Dual Hose Reel System and Method for Transferring Crude Oil

ABSTRACT

A system for transfer of crude oil from a production platform to a tethered barge is provided, comprising one or more hose reels which include swivels to facilitate connection/flanging while the hoses are being deployed into the water or retracted. The reels employ a semi-closed design which helps to contain spills. A floating hose is employed to eliminate the need for buoys or floats which must be attached to the hose as it is being deployed from the reel, or detached as the hose is retracted back onto the reel. A buoy is also used on either side of a KLAW device for connecting the hoses. The KLAW device includes shut-off ball valves on either side, and the KLAW device is adapted to separate when a predetermined level of tension is reached on the hose segments it connects.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit under 35 U.S.C. §119(e) to provisional application Ser. No. 61/804,054, filed Mar. 21, 2013.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT

Not applicable.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates generally to devices and methods used in the transfer of crude oil and other fluids from offshore drilling and production platform to barges, and more particularly to those devices and methods which require break-away couplings.

2. Description of the Invention

Described herein is a simple, safe, efficient, and speedy method of transferring crude oil from a production platform directly into a tethered barge, as shown in FIG. 1. This method is centered around two modified and improved hose reels (1)—one on the production platform (2) and the other on the barge (3), which is tethered on the downwind side of the platform at a safe distance—and sections of flexible floating hose (4) joined by a breakaway coupling (a BAC, or KLAW device) (5).

In this application, barges are used when pipelines cannot be constructed on the bottom of the sea due to severe sea bottom terrain elevations. This oil transfer method is much faster and cheaper to use in the field than the method currently in use for such a transfer. Speed is enhanced by the fact that floating hose does not need to be clamped with buoys or floats every 25 feet or so—which buoys must also be removed from the hose as it is retracted—and is also safer not only for the environment by virtue of the KLAW device, but safer for personnel in the event of a decoupling at the KLAW device when non-floating hose is used. With floating hose, personnel on the barge are required to manhandle a whip line to retrieve a section of hose which could weigh as much as two tons. If the hose on the barge must be reeled in completely, as many as seven (7) buoys must be removed from the hose as it spools back onto the reel. On the production platform side, personnel will not need to scramble to secure a hose wrapped around structural components of the production platform in the event of KLAW separation. The ability to quickly reel in hose (4) from either side (platform or barge) is greatly facilitated by virtue of the facts that 1) the hose itself floats, and 2) does not need, therefore, attached buoys to remain afloat. This transfer method, however, does employ one buoy (6) on either side of the KLAW device (5) to make it and its component halves (in case of separation) more visible. These buoys (6) in no way impede the deployment or recovery of hose. Visibility of the hose (4) in the water is enhanced by the bright color of the hose skin. Each side of the KLAW device (5) is further isolated by a shut-off ball valve (7) which facilitates removal of the device if separation in the water occurs. This method also calls for the inclusion with the hose reel of a spare KLAW device to be available if needed. Modifications to the hose reel are described below as are all components of this oil transfer method.

The hose reel shown in FIG. 2 is to be fabricated with an integral swivel connector (8) which allows the product hose from the production platform (2) to be attached (via flange fittings) to the swivel (8) at the reel at the same time the hose is being deployed. The design also employs a shut-off ball valve (10) between the product hose from the platform and the swivel. Use of a swivel connector (8) at the hose reel (1) saves time because there is no need to wait until the platform-to-reel connection has been secured before deploying the hose, or spooling it back onto the reel. This greatly increases speed and safety.

The improved hose reel, which is also designed in this application with a steel skirt (11) to contain a certain amount of oil in the event of a spill, can be used interchangeably on either the production platform (2) or the barge (3); they are identical in construction and features.

Included in the design and fabrication of the improved hose reel is a hose guide (9) with a “levelwind” device which automatically layers the hose back and forth across the reel to assure smooth and easy feeding as the hose is deployed and then coiling as the hose is retracted. This automatic hose layering system (9) eliminates the need for the workers who previously were required to stand in front of the reel to manually move the hose guide from side to side as the hose was deployed or retracted. This saves time and money, and is a much safer operation.

The automatic hose guide (9) is constructed with Teflon coated rollers to reduce friction between the hose and the hose guide, making deployment and retraction of the hose much smoother. This will also reduce strain on the “levelwind” device and wear on the hose.

The hose guide moves automatically by means of a “levelwind” device or gear similar in design to that found on most bait casting fishing reels, but engineered, scaled up, and machined to handle the weight of the hose and the stresses associated with this offshore application. The device to be used in this hose reel application is geared directly to the hose reel so that the “levelwind” gear is synchronized to turn when the hose reel turns assuring smooth and easy feeding as the hose is deployed or retracted.

The hose reel is turned and operated by means of an air-driven motor sized to provide the needed torque to handle the weight and stress associated with this application.

The hose reel is sized to accommodate at least four hundred (400) feet of floating hose (Super Drillmaster 4″ ID) with an outside diameter of approximately seven (7) inches). Empty this hose weighs 8.74 pounds per foot, according to the manufacturer's specifications for the preferred hose. Four hundred feet of floating hose weighs 3,496 pounds (1.75 tons) when empty. With product (crude oil) included, each foot of this hose weighs approximately 13.5 pounds, bringing the weight of 400 feet of loaded floating hose to 5,398 pounds (2.7 tons). The hose reel and its components are designed to accommodate this weight with an added safety factor.

This oil transfer method requires the use of a floating hose (4) designed for this specific application, as shown in FIG. 3.

Each hose reel will accommodate at least 400 feet of floating hose.

The Super Drillmaster 4″ ID floating hose manufactured by IVG (PL Fuel SD 300 Float) is the preferred hose for this application, but equivalent floating hose with the same bending radius (32″) can be used. Floating hose with a longer bending radius cannot be used in this application unless the hose reels are modified to accommodate the longer radius.

With the elimination of buoys clamped or otherwise attached to the hose every 25 feet or so, both deployment and retraction of the floating hose from/to the production platform or the barge, are accomplished quickly, safely and with less personnel.

The BAC device (5) (or KLAW) shown in FIG. 3 allows the floating hose (4) from the production platform (2) and the receiving barge (3) to be joined. This device has the same internal diameter as the floating hose.

In the event of separation, which could be caused by wind and/or wave action, when the two hose segments are deployed in the water, the KLAW (5) permits only a small amount of oil (approximately one-half to one gallon) to be lost into the sea.

In the event of separation, the hose segments (4) can be quickly reeled onto the production platform (2) and barge (3), respectively, since there is no need to remove neither buoys nor un-flange feeder/discharge hoses in order to permit the hose reels to turn.

Once retracted, the KLAW device (5) is isolated by means of a shut-off ball valve (7) and removed from the hose and replaced with a new unit. All this can be done without draining the hose or de-coupling or de-flanging the hose reel from either the production platform or the barge.

Once the KLAW (5) is removed or detached from the hose via a flange, a new one is attached and the hose is deployed once again. The KLAW is attached in the water and valves (7) opened to allow product to flow once again from the production platform to the barge.

SUMMARY

The key characteristics of this safe, efficient and quick oil transfer method of the present invention are as follows.

First, the ability to quickly deploy or roll out flexible floating hose (4) from the production platform (2) and the barge (3) from specially modified and improved hose reels (1) as these are being connected to platform and barge. There is no need to roll out hose before connecting to platform or barge. The integrated swivel connectors (8) eliminate this delay.

Second, the ability to quickly and efficiently deploy or roll up flexible floating hose from either reel because of a special automatic levelwind device (9) incorporated into the design of the modified hose reel. This levelwind device does not require personnel to manually guide the hose back onto the reel in layers.

Third, use of flexible floating hose on both reels thereby eliminating the need for buoys to keep the hose afloat. This greatly speeds deployment or retraction of hose segments; buoys do not need to be attached or detached from the hose.

Finally, the ability to quickly change out and replace a KLAW device (5) which has separated by virtue of fast hose recovery and the use of shut-off valves (7) on either side of the KLAW device (5). This means that there is no need to pump crude oil from the hose before removing the separated KLAW and attaching the spare device which is shipped with the hose reel. 

What is claimed is:
 1. A system which greatly facilitates the safe, efficient and environmental friendly transfer of crude oil from a production platform (2) and a tethered barge (3) comprising: a. Specially modified and fabricated hose reels (1) which include swivels (8) to facilitate connection/flanging while the hoses are either being deployed into the water or retracted. Reels employ a semi-closed design (11) which helps to contain spills. b. Use of an levelwind device (9) on the hose reel to automatically position the hose correctly on the hose reel particularly during retraction, thereby minimizing delays and the need for personnel to manually guide the hose. c. Use of air-drive motor to turn reel during deployment and retraction of flexible floating hose and to reduce fire hazard on both production platform (2) and barge (3). d. Use of a flexible floating hose (4) to eliminate the need for buoys or floats which must be attached to the hose as it is being deployed from the reel, or detached as the hose is retracted back onto the reel. However, a buoy (6) is used on either side of the KLAW device. e. Use of a KLAW device (5) with shut-off ball valves (10) on either side. The KLAW is designed to separate when a certain level of tension is reached on the hose segments it connects. In the event of a separation, a very minimal amount of crude is spilled, only the amount contained between the internal closure plates of the device, usually less than a gallon. Separation of the device may be caused by wind and/or wave action. f. Shut-off ball valves (10) on either side of the KLAW device (5) allow the two halves of the device to be removed safely when the valves are closed. In this scenario, a new KLAW can be quickly attached. g. A sleeve on the production platform which allows the floating hose to hang over the side of the platform clear of obstructions as it is being deployed or retracted. This sleeve, referred to as a hang-off device, can be swiveled back to the production platform to allow a worker to attaché or remove the KLAW device. 